VERTICAL PRE-MIXER OWNER'S MANUAL PRODUCT DEVELOPMENT ENGINEERING - APRIL, 1998.VERTICAL PRE-MIXER EI MANA56 KEPLERIAIEBER | owner's MANUAL LIST OF VALID PAGES __PAGES PAGES MODE COVER LVo1 06/14/1998 A PRESENTATION INDEX Gos PCOS PGO7 PGo8. G09 PG10 PGIL PGI2 PGI3 PGI4 PGIS PGI6 PGIT PGs PGi9 Pa Pa2i Paz Pas PG24 6/11/1998 A PG2S 06/11/1998 A NOTE: CHECK THE TABLE ABOVE TO SEE IF YOUR MANUAL IS UPDATED. EM PORTUGUES: El MAN 340 4000003347 DATE: 15.02.1999 NAME: LUCIANE KNEBELKAMP SION Zreave X, DATE: 06/11/1998 BY: ROBERTO PAULAVERTICAL PRE-MIXER EIMAN456 KEPLERINEBER’ PRESENTATION Dear Customer, At first, we would like to express you our pride in recording you among the owners of a Vertical Pre-mixer, with our trade mark "KW". In addition, we would like to congratulate you owing to your choice for an ‘equipment of the reknowed mark "KW", sine we can assure you that you will be able to recognize its quality, as well as the efficiency of our Permanent Technical Assistence, no matter when requested. Next, we are going to present you the "Owner's Manual of the Vertical Pre-mixer, which we are sure will greatly help you for its most efficient performance, for its endurance and, above all, to help you to be acquainted with all units and details of your Vertical Pre-mixer. Yours faithfully, KEPLER WEBER INDUSTRIAL S/A Dates / / Modif.: By:VERTICAL PRE-MIXER AEPLERINEBER’ wwoex EIMAN456 1-Introducton 2 -Vertical Pre-mixer 3 -Table of capacities and dimensions. 4 - Operation... 4.1 - Installation of the machine. 5 - Maintenance. 5.1 - Structure. . 10 5.2 - Screw conveyor 53- V-Belts 5.4- Bearings 3.4.1 -Soun 5.4.2 -Temperature 5.4.3 - Lubrication 5.4.4 - Disassembly 5.4.5 - Assembly ... 4 5.5 - Bearings... 5.6 -Cleaning, 6- Drive 6.1 - Electric motor 6.2 - Lubrication of bearings of electric motor 6.3 - Replacement of bearings 7 - General recommendations 8- Spare parts DATE: / / Moor. BY:VERTICAL PRE-MIXER EIMAN456 AEPLERINEBER' OWNER'S MANUAL 5 1 INTRODUCTION The Owner's Manual of the Vertical Pre-Mixer, is to be referred with extreme attention, since its advises and instructions will be very useful for a perfect performance of the equipment. Date: / Modif.: By:VERTICAL PRE-MIXER EI MAN456 KEPLERWEBER| omersuawn | « 2 -VERTICAL PRE-MIXER Vertical Pre-Mixers models PMV - 15 and PMV - 30 were developed from the integrated grinding system,warranting an efficient pre-mixing of all components to be grinded, not submitted to initial granulometry, specific weight and percentage in composition of the formula. This method enables a homogeneity of mixture of different materials ( grain and bulk ), thus guaranteeing a more uniform performance of the mill and reducing the requirement of operators. Their strongness and easy maintenance distinguish them by means of serving many market's demands with cycles of adequate and efficient pre-mixture, thus allowing a continuous flow of the components to be grinded. DATE: f / MODF. BY:VERTICAL PRE-MIXER ad ; AEPUERIVEBER’) owner's MANUAL 7 3.- TABLE OF CAPACITIES AND DIMENSIONS moos. | a | B | c | oD Far a con) (oy) _| MAX. (un) puv-15 | #1200 | 2700 | 1200 | 429¢ [o. 250] 304 | 7,5 15 puv-30 [#2005 [3000 | 1504 | 4794 | a. 250[ 290 15 30 DATE: / / MODF.: BY:VERTICAL PRE MIXER eee KEPLER Wi EBER OWNER'S MANUAL 8 4- OPERATION Discharge flow and maximum capacity of the Vertical Pre-mixer are connected directly with its perfect feeding. Feed Vertical Pre-mixer only when helix is in movement. To prevent from clogging, do not overload it ‘When in the beginning of operation, it is recommended to fill in the pre-mixer without turning mill feeding on in order to proceed a perfect mixture of the ingredients. Open mill feeding only after second loading of scale, providing its discharge after that. Proceed in the same way successively to prevent pre-mixer to work with too little product inside, thus decreasing its efficiency. 4.1 - INSTALLATION OF THE MACHINE To have a perfect working condition, the Vertical Pre-mixer must be assembled and fixed on a solid foundation. Prior to the start up, some basic instructions are to be followed: - Check the correct locking of the top cover, since this leads to a perfect tightness. If necessary, adjust the snap fasteners. - Check if the motor and bearings are correctly attached. - Check if the feeding system is correctly assembled. - Check the correct electric connection of motor and accessories. = Check if V - belts of drive are correctly set on pulleys. Date: / / Modif.: By:EIMAN456 KEPLERINEBER’ = cwnews manu | 9 5. - MAINTENANCE WARNING: "TO ACCOMPLSH ANY REPAIR, MAINTENANCE OR CLEANING, ALWAYS REMOVE THE ELECTRIC FUSES FROM CONTROL BOARD." 5.1 - STRUCTURE For a higher durability of the structure, it is recommended to notice the following items strictly: - Rasp, sand and paint the rust parts on the bolted joints. ~ Check the outside and inside bearings - Tighten screws when they are loose, and keep cover closed. 5.2 - HELIX The following items should be noticed: - Check wearing of helix periodically. - When on maintenance, check for straw and strings around the inside bearing. Date; / / Modif.: ByVERTICAL PRE-MIXER CUTTS KEPLER WEBER’ OWNER'S MANUAL 10 5.3-V-BELTS V-belts tend to stretch after a certain time of use, therefore they should be inspected at regular intervals. If the belts are seen to vibrate a lot or skidding on pulley, check their tension and the alignement of the pulleys. To check proper belt tension, depress each belt with the thumb at a point midway between pulleys forming an arrow with an approximate deflection of 1/100 ( refer to fig. 4 ). REMARK : Deflection of 1 mm for each span of 100 mm. The deflection force should be always perpendicular to span. After the belts have been working for some hours, adjust the tension again. To check the alignment of the belts, refer to fig. 5, Check if pulleys are firmly set on the shafts. Belts should not operate in slack condition. ‘When replacing the belts, proceed as follows: - Use always a set of "V" belts with same number, code and manufacturer. - Untighten the screw jacks and pull the belts out. - Clean off any oil, grease, rust and remove any roughness from the channels of the pulleys prior to place the new ones. - The new set of belts should be easy installed without any tool ( see figs. 6 and 7 ) = Tension the belts again and check their alignment ( refer to figs. 4 and 5 ). Dates) / Modif. By:KEPUERINEBER cwnews wan. | 1 EI MAN456, FIGURE 5 FIGURE 6 - WRONG. FIGURE 7- RIGHT 5.4- BEARINGS Bearings assembled in machines where their stopping cause serious harm should be checked regularly. Notice some cautions during operation, as follow: Date: 1] Modif. By:VERTICAL PRE-MIXER KEPLERINEBER) owners manuat EI MAN456 12 §.4.1- SOUND Place a piece of wooden stick or a screw driver against the housing, as close as possible to the bearing. Put an ear to the other end and listen. If all is running well, a smooth sound should be heard. The sound of a damaged bearing is quite different and may be irregular. If in doubt, disassemble and check the bearing. 5.4.2 - TEMPERATURE ‘Check the temperature of the bearing by simply placing a hand against the housing. If the temperature seems to be above regular, or ‘subject to sudden changes, it should be taken as a hint that something is wrong. In that case, disassemble the bearina and check it 5.4.3 - LUBRICATION Bearings of the Vertical Pre-mixer are already furnished with an adequate amount of grease. Replacement of grease should be done at each 4,000 running hours or from 6 to 6 months. ‘The proceedings to replace grease are as follows: - Untighten the screws from the cover and remove it. - Remove all used lubricant from bearing. - Thoroughly clean out bearing housing and bearing, preventing from any foreign matter. ~ Put clean grease in the bearing. The amount of grease in the free ‘space (raceway of bearing) must be slightly less than one third from this space. - lfnecessary, replace the felt rings. They should be dipped in hot oil with a temperature until 80° C during some minutes before assembly. Be careful to install them correctly in the grooves. ete Baa /eae Modif. By:VERTICAL PRE-MIXER Se KEPLERINEBER’ OWNER'S MANUAL 13 CAUTION: Use always MAX LUB GP BARDAHL, NLGI 2 viscosity, lithium grease or equivalent. Do not overgrease. Too much grease can be as harmful for bearings as too litte. 5.4.4 - DISASSEMBLY To disassemble the bearing, place a piece of pipe or a similar tool against the securing nut and apply evenly spread blows until the bearing comes free from its bushing. When the face of the securing nut is unreachable, the tool should be applied to the face of the bearing's inside ring Dats ae eee Modif. By:VERTICAL PRE-MIXER Eee KEPLERINEBER’ OWNER'S MANUAL 14 5.4.5 - ASSEMBLY ‘The proceedings to assemble the bearing should be the following: - Put the bushing on the shaff, in the place marked prior to disassembly. This can be done easily if the split in the bushing is widened slightly with the help of a screwdriver. ~ Mount the bearing and the lock washer on the bushing and screw on the securing nut. = The reduction of the internal play should be checked by turing the bearing and disaligning the outside ring, - When the nut arrives at the correct degree of tightness, it will be possible to turn the ring easily, but there will start to be a certain resistence when trying to disalign it. REMARK: In case of a new bearing, remove the ANTIRUST coating on it prior to assembly. 5.5 - BEARING FIGURE 11 Date: / / Modif By:VERTICAL PRE-MIXER Bur KEPLERWEBER OWNER'S MANUAL 15 During assembly, bearings should not be blocked on shaft until housings be attached firmly on support surface. Thus, the bearing will take its correct position on shaft without any prejudice. To prevent the possibility of damage to bearing due to harmful installation, the bearing unit should be assembled according to the following instructions: - Introduce the unit on shaft in a sliding way. - Never hammer on the ends of the inside ring, - Attach bearing on its proper place. Spin shaft with the hand to feel if it is rotating freely. 5.6 - CLEANING After a long stop of the Vertical Pre-mixer or when changing product, proceed a general cleaning. Open the cover and start cleaning by removing the objects that block up the flow, such as straw, string, etc. Proceed also a cleaning of the outside of bearings and motor. Do not give hazard a chance. So, never open the cover when the machine is stil running. Dates / / Modif.: By:VERTICAL PRE-MIXER eee Ké PLER Wi EBER’ OWNER'S MANUAL 16 6- DRIVE Drive of the Vertical Pre-mixer is made by an electric motor and it is transmitted by pulleys and belts. 6.1 - ELECTRIC MOTOR Voltage and amperage of electric motor should be checked during operation of Vertical Pre-mixeri. Amperage should not exceed the nominal amperage of the motor. ‘The sounds of the motor should be noticed at irregular intervals. With practice, one’s ear can perfectly detect unusual sounds. 6.2 - LUBRICATION OF BEARINGS OF THE ELECTRIC MOTOR Bearings in an electric motor are supplied with enough grease for a long time. Under regular working conditions, greasing should be spaced in the following intervals: For six-pole motors: 4.5CV to 4.0CV = 20,000 hours 5.0CV to 7.5CV 16,000 hours For four-pole motors: 7.5CV = 15,000 hours 40.0 CV = 10,000 hours When executing these operations, caution is recommended so as to avoid the slightest penetration of grit or dust that could damage the bearings. Dates / / Modif. By:(KEPLERINEBER VERTICAL PRE-MIXER OWNER'S MANUAL EIMAN456 17 If the motor does not have any nipple for greasing, it should be done by the time of a general overhaul when all of the motors are going to be dismantled. ‘Once the motor has been stripped, and without taking the bearings off of the shaft, all the grease should be cleaned off and the bearings washed in kerosene or turpentine until totally clean. After washing, right away put clean grease into the spaces between the balls or rollers and the bearing cages. Do not overgrease. Too much grease can be as harmful for bearings as too little. Never spin dry bearings after washing. For inspection purposes, apply a few drops of light oil. FIGURE!s The follwing table shows the recommended greases to use in bearings of electric motors and the specific manufacturer: GREASES RECOMMENDED FOR MOTOR BEARINGS (Working temperature from - 20 to 130° C) MANUFCT.| GREASE | MANUFCT.| GREASE Esso Beacon 2 Atlantic Lithoiine 2 Shell Aivania R2 Ipiranga | Isaflex EP2 Petrobras | LubraxGMA2 | Texaco ‘Multitak 2 TABLE2 Date: / / Modif.: By:VERTICAL PRE-MIXER KEPLERIVEBER OWNER'S MANUAL EIMAN466 18 6.3 - REPLACEMENT OF THE BEARINGS Disassembly of a motor to replace a bearing should be done by qualified personnel only. Therefore, if a bearing replacement of a motor is required, call for the Technical Assistance. Date: / / Modif. By:KEP LER W. EB ER’ OWNER'S MANUAL VERTICAL PRE-MIXER EIMAN456 19 7- GENERAL RECOMMENDATIONS We take for sure that any customer has his own maintenance system. In such case, to have an efficient and saving maintenance, we recommended to pay attention to the points focused until now. Bearings are initially lubricated by the manufacturer with a high quality grease. The manufacturer advises periodic lubrication. Check the fixings of the bearings periodically. Regarding to wearing, never allow any part to wear completely. When finding out that a'part will last only for a short period, it is worth to substitute it at once than wait for a breakage, possibly during processing period. ‘An unprogrammed breakage is more expensive than a preventive change, since it stops the grain processing completely. The fact of changing wearing parts is not always the best solution. After the replacement, the following items should be noticed: - Bearings should be lubricated correctly. = Never run the equipment without a correct lubrication. Atlast, a overhaul once a year results in a correct positioning about the equipment conditions, thus guaranteeing a perfect performance as well as its conservation. ee Modif. By:AEPLERINEBER’ VERTICAL PRE-MIXER OWNER'S MANUAL ET MANA56 20 8- CODES OF SPARE PARTS CODE DESCRIPTION 8110536717 | 7.5 CV TRIPHASIC MOTOR: 9116182516 | 15 CV TRIPHASIC MOTOR 9114157832 | DP 450 -3A DF 40 PULLEY 9116182338 | DP 560 - 2A DF 40 PULLEY 1108011052 | A 150- V- BELT 1108011583 }| A 158- V- BELT 1128520114 | 32008X BEARING 1128040090 | 1209K BEARING 1128752090 | _H209 ATTACHMENT BUSHING DATE: / / MODF.: BY:EIMAN456 KEPLERINEBER) owners anus | 2! * FOR ANY ADDITIONAL EXPLANATION, THE TECHNICAL DEPARTMENT OF KEPLER WEBER INDUSTRIAL S/A WILL BE ALWAYS AT YOUR DISPOSAL TO SOLVE ANY DOUBT YOU HAVE. * THIS MANUAL WITH TECHNICAL DESCRIPTION AND INSTRUCTIONS OF OPERATION AND MAINTENANCE WAS ACCOMPLISHED BY THE ENGINEERING DEPARTMENT OF KEPLER WEBER INDUSTRIAL S/A. ALL DRAWINGS AND INFORMATION HERE INCLUDE ARE PROPERTY OF KEPLER WEBER INDUSTRIAL SIA. NO PART OF THIS DOCUMENT MAY BE REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING OR OTHERWISE, WITHOUT OUR PRIOR WRITTEN PERMISSION, IN ACCORDANCE TO THE LAW. Date: / of Modif.: By:KEPLERINEBER' THE CUSTOMER EIMAN 456 22 KEPLER WEBER ‘The Engineering Department of Kepler Weber Industrial S/A elaborated this technical manual to elucidate any doubt you could have concerning to the operation, and to give you directions on how to install and maintain the purchased equipment. We hope we have reached our goal. ‘The evaluations and suggestions that you may add to this manual will be of highly importance to us to update it and to raise its quality. QUESTIONNAIRE: Company Address Name Occupation Telephone/Fax for contact, Model of Machine ——— 4) Display a) Shape: ( ) Adequate ( ) Small ( ) Big b) Concerning to handling: ( ) Excellent ( ) Good ( ) Awtul c) Durability of the stuff: ( ) Excellent ( ) Good ( ) Awful 2) Arrangement: a) The chapters (general data, components, start up proceedings, operation and adjustment, cleaning and maintenance, spare parts ) are: ( ) Correct (_) Chapters are missing (_) More titles per chapter b) The approach to the dividing system is: ( ) Easy ( ) Fair ( ) Hard Date; / / Modif.: By:EI MAN 456 KEPUERINEBER) oes 2s KEPLER WEBER 3) Content: a) Related to comprehension of the text: ( Easy (Fair (Hard b) Does the technical information elucidate all your doubts ? ( Yes (No Ifyour answer is "No" , please check the precarious item(s) and describe the problem you are experiencing: ) General data ) Components ) Start up proceedings ) Operation and Adjustment ) Cleaning and Maintenance ) Spare parts c) Does the illustrations present the items mentioned on this manual clearly ? ( Yes (No ( )Some If your answer is " Some * , please describe the problems you are experiencing : Date: / / Modif By:THE CUSTOMER Eee KEPLERIVEBER) cnt cocn 24 4) Are the connections of the items with the illustrations clear? ( )Yes (No ( ) Some IFyour answer is " Some " , please describe the problems you are experiencing: e) Do you miss any illustration to explain a specific item? ( )Yes ()No ( ) Some If your answer is " Yes " or Some " , please describe the problems you are experiencing: ‘Thanks for taking your time to fill out this questionnaire. Please send it to us by fax or mail to the following address: Kepler Weber Industrial S/A clo Engineering Department ‘Ay. Adolfo Kepler Junior, 1500 98280-000 Panambi-RS Brazil Fax; 55 (055) 375 - 1546 Date: osit1r1998 Modif: a By: ROBERTOyy THE CUSTOMER ae KEPLERINEBER’ a i KEPLER WEBER Panambi - Factory No.1 ‘S40 Paulo Rua Hermann Meyer, 43 - Cx. Postal 2 Alameda Olga, 177 Telephone 55 (055) 375 4000 Barra Funda Fax 55(055) 375 4055 Telephone 55(011) 825 7433 CGC 87.288.940/0001-06 Fax 55(011) 67 2002 Inser. Est. 090/0016116 CGC 87.288.940/0018-54 Panambi - Factory No.2 Av. Adolfo Kepler Jtinior, 1500 Telephone 55 (055) 375 3212 Fax 55(055) 375 3166 98280-000 - Panambi- RS CGC 87.288.940/0002-97 Inser. Est. 090/0016124 Panambi - Parts and Service Dept. Rua Gaspar Martins, 459 Telephone 55 (055) 375-4000 Fax 55(055) 375 4277 98280-000 - Panambi - RS CGC 87.288.940/0003/78 Inser, Est, 090/0016132 Porto Alegre Av. Andarai, 566 Telephone 55 (051) 341 1044 91350-1 10 - Porto Alegre - RS CGC 87.288.940/0011-88 Inscr. Est. 096/2029645 Cascavel Av. Presidente Tancredo Neves, 1643 Telephone 55(045) 225 1099 85804-260 - Cascavel - PR CGC 87.288,940/0005-30 Inscr. Est. 41.007.959-A Inscr. Est. 113.603.879.115 Goiania Rua S-1, 260 Quadra 146 - Lote 21 Setor Bela Vista Telephone 55 (062) 255 7888 Fax 55(062) 255 5205 74823-310 - Goiania - GO CGC 87.288.940/0007-00 Inser. Est. 10.179.438-9 Campo Grande Av. Eduardo Alias Zahran, 126 Jardim Paulista Telephones §5 (067) 742 3013 and 742 1114 Fax 55(067) 742 3113 79050-010 - Campo Grande - MS CGC 87.288.940/0004-59 Cuiaba Rua 57, n? 90 Boa Esperanga Telephones 55 (065) 627 1087 and 627 3382 Fax 55(085)627 1885 78068-530 - Cuiaba - MT CGC 87.288.940/0006-10 Inscr. Est, 13.038.135-7 www.keplor.ind.br marketing@kepler.com.br Date : 06/11/1998 Modif.: A By: Roberto Dill Paula